Method of preventing junction leakage in field emission displays

Abstract

A method for fabricating a field emission display (FED) with improved junction leakage characteristics is provided. The method includes the formation of a light blocking element between a cathodoluminescent display screen of the FED and semiconductor junctions formed on a baseplate of the FED. The light blocking element protects the junctions from light formed at the display screen and light generated in the environment striking the junctions. Electrical characteristics of the junctions thus remain constant and junction leakage is improved. The light blocking element may be formed as an opaque light absorbing or light reflecting layer. In addition, the light blocking element may be patterned to protect predetermined areas of the baseplate and may provide other circuit functions such as an interconnect layer.

What is claimed is:  
     
       1. A method of constructing a cold cathode field emission display for preventing junction leakage therein, the field emission display having a baseplate, emitter sites, semiconductor junctions, and a display screen, the method comprising: 
       forming an opaque light-blocking layer between at least one semiconductor junction of the semiconductor junctions and the display screen for blocking photon bombardment by at least one of the display screen, an environment of the field emission display and the display screen, and the environment of the field emission display from the at least one semiconductor junction, the opaque light-blocking layer comprising an insulative light-absorbing material for preventing photons from the at least one of the display screen, the environment of the field emission display and the display screen, and the environment of the field emission display from striking the at least one semiconductor junction of the semiconductor junctions.  
     
     
       2. The method as recited in  claim 1 , wherein the opaque light-blocking layer comprises a layer of material blanket deposited over the baseplate of the field emission display. 
     
     
       3. The method as recited in  claim 1 , wherein the opaque light-blocking layer comprises a layer of material deposited and patterned to protect predetermined areas of the baseplate having the at least one semiconductor junction of the semiconductor junctions. 
     
     
       4. The method as recited in  claim 1 , wherein the opaque light-blocking layer comprises a layer of a conductive material deposited and patterned to protect the at least one semiconductor junction of the semiconductor junctions and to conduct electrical signals within the field emission display. 
     
     
       5. A method for protecting semiconductor junctions in a cold cathode field emission display from photons causing leakage from the semiconductor junctions, comprising: 
       providing a display screen having a phosphor coating;  
       providing a baseplate having a plurality of semiconductor junctions;  
       forming a plurality of emitter sites on the baseplate electrically connected to the plurality of semiconductor junctions and connected to an electrical source, the plurality of emitter sites aligned with the display screen having the phosphor coating;  
       forming a conductive grid for the plurality of emitter sites, the conductive grid connected to the electrical source and separated from the baseplate by an insulating layer to establish a voltage differential to generate an electron emission from the plurality of emitter sites and photon emission from the display screen; and  
       depositing an opaque light-blocking layer for protecting the plurality of semiconductor junctions from at least one photon from the electron emission from at least one emitter site of the plurality of emitter sites striking the display screen causing junction leakage from at least one semiconductor junction of the plurality of semiconductor junctions, the opaque light-blocking layer comprising a light-absorbing material.  
     
     
       6. The method as recited in  claim 5 , wherein the opaque light-blocking layer includes a metal layer deposited on an insulating layer formed on the baseplate. 
     
     
       7. The method as recited in  claim 5 , wherein the opaque light-blocking layer includes an electrically insulating layer deposited on the baseplate. 
     
     
       8. The method as recited in  claim 5 , further comprising: patterning the opaque light-blocking layer to protect predetermined areas of the baseplate. 
     
     
       9. The method as recited in  claim 5 , wherein the opaque light-blocking layer includes a material selected from a group of materials consisting of metal, a polyimide impregnated with carbon black, manganese dioxide and manganese oxide. 
     
     
       10. A method of making a cold cathode field emission display, comprising: 
       forming a plurality of emitter sites having a plurality of emitter tips on a baseplate;  
       forming a plurality of semiconductor junctions on the baseplate with the plurality of emitter tips electrically connected to the plurality of semiconductor junctions;  
       forming a plurality of conductive gate elements for the plurality of emitter sites, the plurality of conductive gate elements electrically separated from the baseplate by an insulating layer, the plurality of conductive gate elements to establish a voltage differential to generate an electron emission from selected emitter sites of the plurality of emitter sites when connected to an electrical source;  
       depositing an opaque light-blocking layer for blocking photons directed at the plurality of semiconductor junctions during use of the field emission display, the opaque light-blocking layer deposited as a layer of material on portions of the baseplate, the opaque light-blocking layer comprising a light-absorbing material;  
       forming a display screen with a phosphor coating, the display screen spaced from the baseplate and aligned with at least one emitter site of the plurality of emitter sites receiving electrons emitted by the plurality of emitter sites generating photons for lighting the display screen during use of the field emission display; and  
       preventing junction leakage of the plurality of semiconductor junctions during use of the field emission display by preventing at least one photon generated by electrons striking the phosphor coating on the display screen from contacting at least one semiconductor junction of the plurality of semiconductor junctions.  
     
     
       11. The method as recited in  claim 10 , further comprising: patterning the opaque light-blocking layer for protecting predetermined areas of the baseplate. 
     
     
       12. The method as recited in  claim 10 , wherein the opaque light-blocking layer includes a metal material. 
     
     
       13. The method as recited in  claim 12 , wherein the opaque light-blocking layer includes a metal layer deposited on an insulating layer.